Rotary perforating machine with means to control web movement



1966 w. F. HUCK ROTARY PERFORATING MACHINE WITH MEANS IO CONTROL WEB MOVEMENT Original Filed July 19, 1960 6 Sheets-Sheet 1 INVENTOR WlLL-H-H I F H K ATToR E Nov. 8, 1966 F HUCK 3,283,636

W. ROTARY PERFORATING MACHINE WITH MEANS TO CONTROL WEB MOVEMENT Original Filed July 19, 1960 6 Sheets-Sheet 2 wwr; 4 Y

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IN VENTOK A TTOR NEY 1966 w. F. HUCK ROTARY PERFORATING MACHINE WITH MEANS TO CONTROL WEB MOVEMENT Original Filed July 19. 1960 6 Sheets-Sheet 5 INVENTQR WILLIAM F HUCK ATTORNZY Nov. 8, 1966 w F. HUCK 3,283,636

ROTARY PERFORA IING MACHINE WITH MEANS TO CONTROL WEB MOVEMENT Original Filed July 19. 1960 6 Sheets-Sheet 4 IN NTOR WILLIAM F H m ATT Y Nov. 8, 1966 w. F. HUCK ROTARY PERFOHATING MACHINE WITH MEANS TO CONTROL WEB MOVEMENT Original Filed July 19. 1960 6 Sheets-Sheet 5 kkO A 6 -.m no 106F338 wxDmmmda MY E N M T T A X 2 IN VFN TOR WILL/A M F HucK 6 Sheets-Sheet 6 HUCK MACHINE WITH MEANS O CONTROL WEB MOVEMENT ROTARY PERFORATING INVEA/TOR WILLIAM F H CK g-rroa Ei Q Q stl lj 0800080008 32 8 g 0300000000 R L sHz-:E-r LENG H United States Patent 3,283,636 ROTARY PERFORATING MACHINE WITH MEANS T0 CDNTROL WEB MOVEMENT William F. Huck, 81 Greenway Terrace, Forest Hills, Long Island, N.Y. Original application July 19, 1960, Ser. No. 43,839. Divided and this application Oct. 15, 1965, Ser. No.

1 Claim. (Cl. 83-365) This application is a division of my copending application Serial No. 43,839 filed July 19, 1960.

This invention relates generally to perforating devices that form patterns of holes in webs of paper, cloth, felt, metal sheet or foil and the like, and is particularly directed to devices for perforating such webs that have been printed with multiple .geometric patterns, for example, as in the case of postage and commercial stamps.

In the past, webs having postage or commercial stamps printed thereon were usually perforated by devices employing reciprocating or oscillating flat die plates. During each operating stroke, the reciprocating or oscillating flat die plates of such perforating devices simultaneously form the rows of holes extending both transversely and longitudinally in a portion of the web representing one or more sheets of the stamps to be produced. Since it is possible to obtain relatively great depth of engagement of the perforating pins in the die holes when using reciprocating or oscillating flat die plates, the clean cutting of the perforated holes can be easily accomplished. Another advantage of the use of reciprocating or oscillating fiat die plates resides in the fact that, in producing such die plates, the plate for holding the perforating pins, the stripper plate and the plate intended to have the die holes can be stacked and then drilled through in a single pass in order to economically ensure the working accuracy of the perforating pins with respect to the holes in the stripper plate and the female die plate.

The major disadvantage of employing reciprocating or oscillating fiat die plates for the perforating of webs is the limitation on the speed of operation inherent in the reciprocation or oscillation of the heavy masses of such die plates while seeking to maintain the relative positional accuracy of all of the moving parts necessary for the perforation of small and closely spaced apart holes.

Most of the existing rotary perforating devices producing holes in rows extending transversely and longitudinally with respect to the web employ two pairs of male and female die cylinders, with one of such pairs of die cylinders forming holes in rows which extend transversely across the web, while the other pair of die cylinders produces holes in rows extending longitudinally along the web. Since the rows of holes extending transversely across the web are usually spaced substantially apart in the direction of movement of the web, there is some freedom of movement for the web between the successive transversely extending rows of perforating pins. This freedom of movement helps to register the position of the web relative to the die cylinders so that the holes in the transversely extending rows are located exactly between the transversely extending rows of printed areas. However, the holes or perforations included in the rows extending longitudinally with respect to the web are very closely spaced apart so that the web has no freedom of movement between the successive perforating pins forming such holes, and registration of the holes in the longitudinally extending rows with respect to the printed areas requires that the die cylinders for producing such holes or perforations be driven at varying speeds which are adjusted to the speed of the web. Such varying speeds of the die cylinders have a tendency to cause tearing or rupture of the web, and the perforating of the web noticeably weakens the latter and may also result in its elongation, but the tension controls employed in the existing rotary perforating devices have been ineffective in firmly and precisely regulating web tension and have been lacking in sensitivity to tension variations so that tearing or rupture of the web occurs quite frequently, particularly when operating at high speeds.

Although it is known that the faulty or inaccurate registration of the rows of perforations with respect to each other and with respect to the printed areas is aesthetically objectionable to many purchasers of postage and commercial stamps, the mainttenance of precise registration during the operation of rotary perforating devices is made difiicult by reason of the fact that the conditions of the printed web, particularly when the latter is formed of paper, are seldom, if ever, uniform, since the printing process subjects the web to moistening, varying atmospheric conditions, heavy printing pressure, heating and cooling, with the result that slight'variations occur in the lengths of the successive printed areas on the web. While such slight variations in the lengths of the printed areas on the web are individually small, the individual variations may accumulate over a number of the successive printed areas and produce a substantial error in registration. While the existing rotary perforating devices employ register controls which seek to compensate for the web variations, these register controls have not proved to be reliable or completely effective at high operating speeds.

Accordingly, it is an object of this invention to provide a rotary perforating device which is capable of successfully operating at a substantially higher speed than that possible with the existing rotary perforating devices.

Another object is to provide a rotary perforating device which is capable of maintaining accurate registration of the rows of perforations with respect to the printed areas on the web, and which automatically and instantaneously adjusts to accommodate variations in the size and spacing of the printed areas on the web, even druing the desired high speed operation.

In accordance with the invention, a rotary perforating device having the characteristics referred to above is provided with photoelectric scanning means cooperating with register marks previously applied to the printed web in order to sense any error in either longitudinal or lateral registration of the printed areas on the web with respect to the perforating die cylinders and, in the event of a sensed error, to suitably actuate longitudinal and lateral registering means so as to effect the necessary correctrons.

The above, and other objects, features and advantages of the invention, will be apparent in the following detailed description of an illustrative embodiment thereof which is to be read in connection with the accompanying drawings forming a part hereof, and wherein:

FIG. 1 is a side elevational view of a rotary perforating device embodying the invention;

FIG. 2 is another side elevational view of the rotary perforating device of FIG. 1, but as viewed from the opposite side thereof and with the side frame of the device being partly broken away;

FIG. 3 is a top plan view of a major portion of the rotary perforating device of FIGS. 1 and 2, as viewed along the line 33 of FIG. 1;

FIG. 4 is a transverse sectional view taken along the line 44 of FIG. 1, and showing a lateral registration mechanism included in the rotary perforating device embodying the invention;

FIG. 5 is an enlarged vertical sectional view taken along the line 5-5 of FIG. 1;

FIG. 6 is a schematic diagram of the controls included in the rotary perforating device embodying the invention for maintaining longitudinal and lateral registration of the printed web with respect to the perforating cylinders, and for engaging and disengaging the cooperating perforating cylinders;

FIG. 7 is a fragmentary plan view of a portion of a printed web which has been perforated in a rotary perforating device embodying the present invention; and

FIG. 8 is an enlarged detail view of a portion of the male die cylinder structure appearing in FIG. 5.

Referring to the drawings in detail, and initially to FIGS. 1, 2 and 3 thereof, it will be seen that a rotary perforating device embodying the present invention and there generally identified by the reference numeral includes spaced apart side frame members 21 and 22 between which there are mounted a rotary perforating unit 23 adapted to form perforations in rows extending transversely with respect to the web W, and a rotary perforating unit 24 which acts on the web following the formation of the transversely extending rows of perforations therein by the unit 23, and which is adapted to form longitudinally extending rows of perforations in the web.

The web W, which has been previously printed with small repetitive patterns P arranged in transversely and longitudinally extending rows, as shown in FIG. 7, enters the rotary perforating device 20 from the top, as shown in FIG. 1, and is initially acted upon by a longitudinal register control mechanism 25 and then by a transverse register control mechanism 26, which mechanisms are arranged in succession and hereinafter described in detail. After being acted upon by the transverse register control mechanism 26, the web W passes under an idler roller 27 arranged in front of the perforating unit 23 and having its opposite ends rotatably journaled in suitable fixed bearings carried by side frame members 21 and 22. After passing through the perforating unit 23, the web travels under idler rollers 28 and 29 which are respectively arranged in back of perforating unit 23 and in front of perforating unit 24, and which have their opposite ends rotatably journaled in fixed bearings carried by side frame members 21 and 22.

After running around the idler roller 29, the web W passes through perforating unit 24 and is acted upon by a web tension control mechanism which is generally identified by the reference numeral 30 and which comprises rollers 233 and 234 engaging the web W at locations in front of perforating unit 24 and in back of the latter, respectively. Following engagement of the web by roller 234 of the tension control mechanism 30 at the location in back of perforating unit 24, the web passes around an idler roller 31 which is disposed in back of perforating unit 24 and has its opposite ends rotatably journaled in fixed bearings carried by side frame members 21 and 22.

As shown in FIG. 5, rotary perforating unit 23 which is intended to form the perforations or holes H in transversely extending rows T (FIG. 7) includes a male die cylinder 32 having a suitably arranged pattern of perforating pins or punches 33 projecting radially therefrom, and a female die cylinder 34 disposed below the cylinder 32 and having a correspondingly arranged pattern of female die holes 35 in its surface to receive the perforating pins 33 as the cylinders 32 and 34 are jointly rotated with the web W passing therebetween, whereby the perforating pins 33 and female die holes 35 cooperate to form the desired holes or perforations in the web.

The male die cylinder 32 includes a body 36 having trunnions 37 projecting axially from the opposite ends thereof and rotatably journaled in bearings 38 which are mounted in eccentric bearing housings 39 'rotatably supported by side frame members 21 and 22.

The female die cylinder 34 also includes a cylindrical body 49 having trunnions 41 projecting axially from its opposite ends and being rotatably journaled in bearings 42 which are mounted in side frame members 21 and 22. It will be apparent that rotation of eccentric bearing housings 3? is effective to displace the axis of rotation of male die cylinder 32 with respect to the axis of rotation of female die cylinder 34. When the eccentric bearing housings are rotatably disposed to provide a relatively small distance between the axes of the male and female die cylinders, the perforating pins or punches 33 of cylinder 32 are engage-able in the corresponding fema'le die holes 35 of cylinder 34. However, when eccentric bearing housings 39 are turned to positions which space the axis of cylinder 32 a relatively large distance from the axis of cylinder 34, the perforating pins are disengaged from the female die holes, thereby to facilitate initial threading of the web through the rotary perforating device, or the replacement or repair of the removable elements included in the cylinders 32 and 34.

Although eccentric bearing housings 39 may be manually turned to effect the engagement and disengagement of the die cylinders 32 and 34, the rotary perforating device 20 embodying this invention preferably includes a pneumatically operated system for imparting the necessary turning movements to the eccentric bearing housings. Thus, as shown in FIGS. 1, 3 and 5, a pneumatic pressure cylinder 43 having a ram or piston rod 44 projecting from one end is pivot-ally mounted, at its opposite end, on a pin 45 projecting inwardly from side frame member 22, and the free end of the piston rod 44 is pivo-tally connect-ed to one end of a bell crank 46 which is fixed to a shaft 47 disposed above cylinder 32 and having its opposite ends rotatably journaled in bearings 48 carried by side frame members 21 and 22 (FIG. 5 The opposite end of bell crank 46 is pivotally connected to a link 49 which is, in turn, pivotally connected to an extension 50 projecting from the eccentric bearing housing 39 mounted in the adjacent side frame member 22. A radial arm 51 is also fixed to the shaft 47 adjacent side frame member 21 and has its end pivotally connected to a link 49 which is, in turn, pivotally connected to an extension 50 pro jectin-g from the eccentric bearing housing 3? carried by side frame member 21. Thus, stroking of the piston rod 44 of cylinder 43 causes turning of shaft 47, and the bell crank 46 and arm 51 cooperate with the links 49 and extension 50 to transmit the turning movement of shaft 47 to the eccentric bearing housings 39.

As shown in FIG. 6, the engagement and disengagement of cylinders 32 and 34 is preferably controlled by an electro-pneumatic circuit that includes a compressed air supply conduit 52 having the usual flow control valve 53, air filter 54 and air llubricator 55 interposed therein in close proximity to the perforating device 20. A branch conduit 56 extends from the compressed air supply conduit 52 to the inlet port 57 of a solenoid controlled valve 58, and a conventional pressure regulator 59 is interposed in branch conduit 56. The valve 58 is provided with an exhaust port 60 and with two exit ports 61 and 62 which are respectively connected by pipes 63 and 64 to the opposite ends of the cylinder 43. The coil of solenoid operated valve 58 is connected to the usual electrical supply lines 65 by way of conductors 66 and 67, and the latter has an onoff switch 68 interposed therein. The valve 58 is arranged so that, when its coil or solenoid is energized by movement of switch 68 to its on position, compressed air flows through exit port 62 and pipe 64 to the right hand end of cylinder 43 while the left hand end of cylinder 43 is connected to exhaust port 60 by way of pipe 63 and exit port 61, so that the piston rod 44 is retracted and causes turning of hell crank 46 and shaft 47 in the counterclockwise direction, as viewed in FIG. 12, to the extent permitted by engagement of the lower arm of the bell crank with a stop pin 69 projecting from the adjacent side frame member 22 into the path of movement of the bell crank. Engagement of the bell crank 46 with the stop pin 69 corresponds to the position of eccentric bearing housings 39 for effecting engagement of cylinders 32 and 34. On the other hand, when the solenoid or coil of valve 58 is de-energized, by movement of switch 68 to its off position, valve 58 connects the left hand end of cylinder 43 to the source of compressed air, by way of the pipe 63 and exit port 61, while the right hand end of cylinder 43 is connected to the exhaust port 60 by way of pipe 64 and exit port 62, thereby to permit the elastic expansion of the compressed air in cylinder 43 at the left hand side of the piston which causes extension of piston rod 44 and clockwise turning of bell crank 46 and shaft 47 to the extent permitted by the engagement of the bell crank with a stop pin 70 which also projects from the adjacent side frame member 22 into the path of movement of the bell crank. Engagement of the bell crank 46 with stop pin 70 corresponds to the disengaged position of the male die cylinder 32 with respect to female die cylinder 34.

The rotary perforating device 20 is driven in synchronism with an associated web processing machine (not shown), for example, a printing press for applying the repetitive printed patterns P to the web prior to the perforating of the latter in the device 20, or a cutting and stacking machine which receives the perforated web from the device 20 and cuts the web into sheets of predetermined size which are then suitably stacked, the desired synchronous drive of the rotary perforating device 20 being derived from a suitably rotated main drive shaft 71 (FIG. 1) running horizontally above the perforating device and carrying a bevel gear 72 meshing with a bevel gear 73 at the upper end of a vertical transmission shaft 74. The lower end of transmission shaft 74 carries a bevel gear 75 meshing with a bevel gear 76 secured to one end of a cross shaft 77 disposed below female die cylinder 34 and having its opposite end port-ions rotatably journaled in bearings 78 carried by side frame members 21 and 22. As shown in FIG. 5, the end of cross shaft 77 remote from bevel gear 76, that is, the end of the cross shaft projecting outside of side frame member 21, has a pinion 79 fixed thereon and meshing with a spur gear 80 which is secured to an extension 81 of the adjacent trunnion 41 of female die cylinder 34. Thus, female die cylinder 34 is rotated from cross shaft 77 by way of the meshing pinion 79 and gear 80, and the male die cylinder 32 is driven from the gear 80, preferably by way of a backlash take-up gear 82 which is mounted on an extension 83 of the adjacent trunnion 37 of the male die cylinder and which is of the type disclosed in detail in US Letters Patent No. 2,911,847 issued November 10, 1959 to W. F. Huck. Such a backlash take-up gear gene-rally includes two relatively narrow gears 84 and 85 mounted on a common hub and rotatable independently with respect to the latter, and a spring actuated linkage connected to gears 84 and 85 to urge the gears to turn equal distances in opposite directions with respect to the common hub, thereby to take up any backlash between the teeth of the gears 84 and 85 and the meshing teeth of the conventional spur gear 80. Thus, the backlash take-up gear 82 is effective to maintain precise rotational alignment between the bodies of cylinders 32 and 34 despite changes in the contours of the gear teeth produced by wear. Further, the teeth of gears 82 and 80 are dimensioned so that meshing engagement therebetween will be maintained even when the eccentric bearing housings 39 are turned to effect disengagement of cylinder 32 from cylinder 34, thereby to ensure that the rotational alignment of the bodies of the cylinders 32 and 34 will not be disturbed during disengagement and reengagement of such cylinders.

The perforating unit 23 forms the holes H in the transversely extending rows T, as previously mentioned with reference to FIG. 7, and also is intended to form slits S which are longitudinally aligned with the longitudinally extending rows L of holes or perforations formed by the perforating unit 24, as hereinafter described in detail, and which are arranged in transversely extending rows E corresponding to the opposite end edges of sheets to be cut from the printed web W following the perforation thereof in the device embodying the invention. The slits S facilitate the tearing of the individual sheets into strips along the longitudinal rows L of perforations.

The male and female die cylinders of perforating unit 23 have circumferences that are equal to a whole number multiple of the sheet length to be cut from the perforated preprinted web, that is, the distance between the successive rows E of slits S.

As shown in FIG. 5, the body 36 of male die cylinder 32 has radially raised, axially directed, circumferential flanges 86 at its opposite ends, and a plurality of circumferential, radially raised ribs 87 at axially spaced apart locations between flanges 86.

As shown in FIG. 5, male die cylinder 32 of perforating unit 23 further includes a circumferentially arranged series of axially extending pin holding bars 88 corresponding to the transversely extending rows T of holes or perforations to be formed in the web W, and one or more knife holding bars 89 carrying knives 108 in a pattern corresponding to the transversely extending rows E of slits S to be formed in the web. The opposite ends of the bars 88 and 89 are secured to the flanges 86 by means of mounting screws 90.

As shown in FIG. 5, body 40 of female die cylinder 34 has radially raised, circumferentially extending ribs 114 at the opposite ends thereof and also at axially spaced apart locations therebetween, and the ribs 114 are formed with axially aligned cutouts 115 at circumferentially spaced apart locations to receive female die bars 116 which correspond, in number and location, to the pin holding bars 88 of male die cylinder 32, and one or more female die bars 117 which contain narrow grooves 126 that correspond, in number and location, to the knives of the knife holding bar or bars 89 of the male die cylinder.

Referring again to FIG. 1, it will be seen that the longitudinal register control mechanism 25 includes a movable roller 127 over which the web W travels and being rotatably supported, at its opposite ends, in arms 128 which extend radially upward from a shaft 129. The opposite ends of shaft 129 are rotatably mounted in suitable bearings carried by upper frame members 130 so that arms 128 and roller 127 can rock, as a unit, about a horizontal axis defined by the shaft 129. A nut 131 is pivotally supported by one of arms 128 and threadably receives an adjusting screw 132 which is connected by a universal joint 133 to the shaft of .a reversible electric motor 134 mounted on the adjacent upper frame member 130.

It will be apparent that, when electric motor 134 is rotated in one direction, for example, to effect swinging of arms 128 in the clockwise direction, as viewed in FIG. 1, the corresponding movement of roller 127 will decrease the length of printed web W between the source thereof, for example, a supply roll of the printed Web, or a printing couple for applying the desired repetitive printed patterns to the web, and the perforating unit 23, thereby to longitudinally advance the printed patterns P with respect to the transverse rows T of perforations formed by perforating unit 23, whereas, when motor 134 is rotated in the opposite direction, roller 127 is displaced to increase the length of the printed web between the source thereof and perforating unit 23, thereby to longitudinally retard the printed patterns P with respect to the transverse rows T of perforations.

The reversible electric motor 134 is actuated in response to detected longitudinal register errors by a photoelectric control system shown in FIGS. 1 and 6. Such a control system includes a photoelectric scanning head 135 which may be of the type commercially available from the Specialty Control Department of General Electric Company, Waynesboro, Virginia, under items No. CR7S15- P202-G4. A scanning head of the identified type generally includes a light source directing a beam of light against an edge portion of the web W at a location between roller 127 of longitudinal register control mechanism 25 and idler roller 27, and a photoelectric detection cell disposed to scan the surface of the web at the location where the light beam impinges thereagainst. As shown in FIG. 7, the edge portion of web W to be scanned by the head 135 has spaced apart register marks R applied thereto. Such register marks are preferably applied to the web during the printing thereof and may be either printed on the web or embossed in the web, or in the form of slits or perforations made in the web. It will be apparent that, when a register mark R passes through the illumniated region or area A scanned by the photoelectric detection cell of head 135, such register mark changes the intensity of light reflected from the web into the photoelectric detection cell and causes a suitable electrical signal to be emitted fiom head 135.

The photoelectric control system for the motor 134 fur ther includes a photoelectric selector switch 136 which is suitably mounted, for example, on a bracket 137 secured to side frame member 22 adjacent perforating unit 23 (FIG. 1). The photoelectric selector switch 136 may be of the type which is commercially available from the Specialty Control Department of General Electric Company, Waynesboro, Virginia, as item No. CR75l5-P145- G4, and generally includes a slotted disk mounted on a rotatable shaft 138, a light source (not shown) directing a beam of light against one side of the slotted disk and a photoelectric cell (not shown) at the opposite side of the slotted disk so as to be intermittently energized by light passing through the slots of the rotated disk and thereby produce electrical pulses or signals at regularly spaced apart intervals. Shaft 138 of selector switch 136 is driven from perforating unit 23 by means of a belt 139 running around pulleys 140 and 141 which are respectively secured to shaft 138 and to an axial extension 142 of the trunnion 37 of male die cylinder 32 which is rotatably mounted in side frame member 22 (FIGS. 1, 3 and 5).

The slotted disk of selector switch 136 is disposed on shaft 138 so that, when the printed patterns P of web W are properly registered in the longitudinal direction with respect to the transverse rows T of perforations to be formed by perforating unit 23, the electrical signal resulting from the scanning of a register mark R by the photoelectric scanning head 135 occurs simultaneously with an electrical signal emanating from selector switch 136. However, if there is a longitudinal register error, the electrical pulse or signal issuing from the scanning head 135 occurs either before or after the corresponding electrical pulse or signal issuing from selector switch 136.

The electrical pulses or signals issuing from scanning head 135 and selector switch 136 are fed, by way of conductors 143 and 144, respectively, to a register control panel 145 (FIG. 6) which is commercially available from the Specialty Control Department of General Electric Company, Waynesboro, Virginia, as item No. 387515- CTlOO-Al, and which may have the assembly of electrical components as illustrated in the wiring diagram appearing between pages 9 and 10 of the instruction bulletin published by General Electric Company under the designation GEI46908B.

The register control panel 145 of the above identified type is operative to amplify the signals received from scanning head 135 and selector switch 136, respectively, and to compare such signals so that any timing discrepancy between a signal resulting from a detected register mark R and a related signal from selector switch 136 produces an error signal which is transmitted to motor 134, by way of conductors 146, and thereby causes rotation of reversible correction motor 134 in the direction for displacing roller 127 so as to overcome the detected register error. Thus, if the detected register mark R arrives too soon at the scanned region or area and therefore gives rise to a signal emanating from head prior to the corresponding signal from selector switch 136, motor 134 is rotated in the direction for swinging arms 128 in the counterclockwise direction, as viewed in FIG. 1, whereas, if the detected register mark lags behind its correct or registered position, the resulting error signal transmitted from control panel to motor 134 produces rotation of the latter in the direction for causing clockwise turning of the arms 128.

As shown in FIG. 6, register control panel 145 draws its power from electrical supply lines 65 by way of conductors 147 and 148, and the latter has a switch 149 interposed therein and provided with three positions in which motor 134 of longitudinal register control mechanism 25 is rendered inoperative, is automatically operated in response to register errors detected in the manner indicated above, or is operated by manual controls, respectively. Such manual controls are in the form of an advance push-button switch 150 and a retard push-button switch 151 interposed in conductors 152 which extend from switch 149 and from conductor 147 to the conductors 146 so that, when switch 149 is in its position for hand or manual control, visually detected, relatively large longitudinal register errors may be corrected by depressing either one or the other of the switches 150 and 151.

The transverse register control mechanism 26 is intended to maintain accurate transverse registration between the printed patterns P on the web W and the longi tudinal rows L of perforations formed in the web by unit 24 of perforating device 20. As shown in FIGS. 1 and 4, transverse register control mechanism 26 includes parallel upper and lower web contacting rollers 153 and 154 having their opposite ends rotatably journaled in bearing blocks 15 which are centrally pivoted on axles 156 carried by the lower ends of arms 157. The arms 157 are suspended from shafts 158 which are rockably supported in brackets 159 carried by the upper frame members 130. As is apparent in FIG. 4, the lateral distance between the axes of shafts 158 is greater than the distance between the shafts or axles 156 measured in the direction parallel to the axes of the rollers 153 and 154 so that, when the latter are in their central position, as shown in FIG. 4, the arms 157 at the opposite sides of the path of travel of web W converge downwardly.

One of the bearing blocks carries a centrally'located nut (not shown) which threadably receives an adjustment screw 160 connected by a universal joint 161 to a reversible electric motor 162 which is suitably suspended from a bracket 163 carried by the adjacent upper frame member 130. Thus, when the reversible motor 162 is rotated in one direction or the other, adjustment screw 160 causes corresponding lateral displacement of rollers 153 and 154 which, by reason of the previously mentioned downward convergence of the arms 157 in the neutral or central position of the rollers, are also tilted or inclined from the horizontal to an extent dependent upon their lateral displacement.

As shown in FIG. 1, the web W passes in front of and then under roller 153 before passing over and in back of the roller 154 so that the tilting action of rollers 153 and 154 that accompanies the lateral displacement thereof is effective to urge the web laterally in the same direction as the lateral displacement of rollers 153 and 154.

In the rotary perforating device 20 embodying the present invention, the reversible correction motor 162 of transverse register control mechanism 26 is energized by means of a photoelectric control system which, as shown in FIGS. 2 and 6, includes a photoelectric scanning head 164 that may be of the type commercially available from the Specialty Control Department of General Electric Company, Waynesboro, Virginia, as item No. 3S75l5PSl02. The scanning head 164 is suitably mounted so that a light source therein will direct a beam of light against the edge portion of web W at the opposite side of the latter from the register marks R and at a location along the web that is intermediate roller 154 and idler roller 27.

As shown in FIG. 7, the edge portion of web W against which scanning head 164 directs a beam of light is preprinted with a transverse register line RT which is in a fixed transverse position with respect to the printed patterns P of the web. The scanning head 164 is laterally located so that, when there is correct transverse registration between the web and perforating device 20, particularly, perforating unit 24 of the latter, the area or region A (FIG. 7) or the web surface which is illuminated by the bear or light from scanning head 164 is exactly bisected by one longitudinal edge of register line RT, and thereby establishes the normal intensity of light reflected from the web to a photoelectric cell included in scanning head 164 during correct transverse register. It will be apparent that any deviation of the transverse position of the web, toward one side or the other, from this correct transverse register position causes a change in the intensity of light reflected by the web from the light sosrce of head 164 into the photoelectric cell of the latter, and thereby alters the voltage generated by the cell.

As shown in FIG. 6, the voltage generated by the photoelectric cell of head 164 is led, by conductors 165 to a register control panel 166 which may be of the type that is commercially available from the Specialty Control Department of General Electric Company, Waynesboro, Virginia, as item No. 3S75l5SR100 and which, as shown in the wiring diagram thereof appearing between pages 18 and 19 of the instruction bulletin published by General Electric Company under the designation GEH- 2121A, generally includes a Wheatstone bridge network that is balanced when the strength of the electrical signal from scanning head 164 corresponds to correct transverse register of the web. Any deviation in the strength of the electrical signal received from scanning head 164 serves to unbalance the Wheatstone bridge which thereby generates an error signal which is sufliciently amplified by a conventional amplifier included in panel 166 and which is led from the latter to motor 162 by way of conductors 167 for energizing the correction motor of transverse register control 26. The resulting rotation of motor 162 is converted by the previously described combined lateral displacement and tilting of the web contacting rollers 153 and 154 into a proportional lateral displacement of the web W tending to restore the desired accurate transverse registration of the web.

As further shown in FIG. 6 register control panel 166 draws its power from electrical supply lines 65 by way of conductors 168 and 169, and the latter has a switch 170 interposed therein and provided with three positions in which motor 162 of transverse register control mechanism 26 is rendered inoperative, is automatically operated in response to register errors detected in the manner indicated above, or is operated by manual controls, respectively. Such manual controls are in the form of a left push-button switch 171 and a right push-button switch 172 interposed in conductors 173 which extends from the position of switch 170 for manual or hand control to the conductors 167 so that, when switch 170 is in its position for hand or manual control, visually detected, relatively large transverse register errors may be corrected by depressing either one or the other of the switches 171 and 172.

In accordance with the present invention, cylinders 174 and 176 of perforating unit 24 are driven at a variable speed which is automatically adjusted in accordance with the tension in web W in order to maintain a desired tension in the web between perforating units 23 and 24 and also at the output of perforating device 20.

As shown in FIGS. 2 and 3, the variable speed drive for the die cylinders of perforating unit 24 includes a pulley 215 secured on the end of cross shaft 77 which projects through side frame member 27, and a V-belt 216 which runs around pulley 215 around a variable diameter pulley 217 which is preferably of the kind disclosed in US. Letters Patent No. 2,812,666, issued November 12, 1957, to W. F. Huck, and which is mounted on a projecting end or extension of a shaft 218 extending laterally below perforating unit 24 and having its opposite end portions rotatably journaled in bearings 219 carried by side frame members 21 and 22. In a variable diameter pulley of the identified type, the radius of contact of belt 216 with variable diameter pulley 217, and hence the transmission ratio between shafts 77 and 218, depends upon the tension in belt 216 and, as will hereinafter be described in detail, the tension in belt 216 is made dependent upon the relative tensions in web W before and after perforating unit 24.

In order to make the tension in belt 216 responsive to the tension in web W, the perforating device 20 further includes floating rollers 233 and 234 respectively disposed in front and in back of perforating unit 24 so that web W travels forwardly from fixed idler roller 29 before passing around floating roller 233 on its way to perforating unit 24, and so that the perforated web travels forwardly from floating roller 234 before passing around fixed idler roller 31 at the exit or outlet of perforating device 20. The opposite ends of floating rollers 233 and 234 are rotatably mounted in the upper end portions of pairs of arms 235 and 236, respectively, and the pairs of arms 235 and 236 are secured, adjacent their lower ends, to laterally extending shafts 237 and 238, respectively, which have their opposite end portions rotatably journaled in side frame members 21 and 22. Links 239 are pivotally connected, at their opposite ends, to arms 235 and 236, respectively, in order to ensure that floating rollers 233 and 234 will have equal displacements at all times.

As shown in FIGS. 2 and 3, shafts 237 projects laterally beyond side frame member 21 and, at its projecting end, carries a radial arm 240 having a take-up pulley 241 rotatably mounted at its free end and engaging the lower run of V-belt 216 from above. Thus, rocking or turning of shaft 237 will cause corresponding displacement of take-up pulley 241 for either increasing or decreasing the tension in belt 216. Downwardly projecting arms 242 are also secured to shaft 237 adjacent the inside surfaces of side frame members 21 and 22, and the lower end of each downwardly projecting arm 242 is secured to a rod 243 which extends substantially horizontally. The opopsite end portions of each rod 243 extend loosely through blocks 244 which are suitably secured to the inside surface of the adjacent side frame member 21 or 22, and compression springs 245 extend around each rod 243 between the opposite sides of the related downwardly projecting arm 242 and the stationary blocks 244.

A radical arm 246 is secured to shaft 238 adjacent the inside surface of side frame member 22 and, at its free end, is pivotally connected, as at 247, to the upper end of a rod 248 which is secured to a piston slidable within a cylinder 249 having its lower end pivotally mounted, as at 250, on the adjacent side frame member 22. Cylinder 249 is filled with a reltaively viscous fluid which acts on the piston of rod 248 to effectively dampen relatively high frequency reciprocations of the piston, and hence the corresponding high frequency oscillations or hunting of shaft 238, arms 235 and 236 and floating rollers 233 and 234. An end of shaft 238 projects laterally beyond side frame member 22 and carries a pointer arm 251 which coperates with a dial or scale 252 secured to the side frame member to indicate the positions of floating rollers 233 and 234 at any instant.

The initial positions of floating rollers 233 and 234 are determined by at least one tension spring 253 which is connected, at its opposite ends, to a pin 254 on the arm 236 adjacent side frame member 22 and to a pin 255 carried by an arm 256 which extends radially from the inner end of a pivot shaft 257 rotatably carried by the adjacent side frame member 22. The outer end of pivot shaft 257 has a radial arm 258 secured thereto and carrying a nut 259 which is threadably engaged by a screw 260 rotatably mounted in a bracket 261 secured to side frame member 22. A hand wheel or knob 262 is secured to the upper end of screw 260 in order to permit manual rotation of the latter which effects turning movement of pivot shaft 257 and of the arm 256, whereby the initial tension in spring 253 can be adjusted. Further the outer end of shaft 257 carries a pointer 263 cooperating with a dial or scale 264 secured to side frame member 22 in order to indicate the position of arm 256, and hence the initial tension in spring 253.

It will be appreciated that the arms 235 and 236 and the links 239, considered as a unit, are maintained in equilibrium by a balancing of the forces resulting from the web tension in advance of perforating unit 24, as sensed by floating roller 233, the web tension following the perforating unit 24, as sensed by floating roller 234, the tension in V-belt 216 which acts on take-up pulley 241, the tension in spring 253 connected to one of the arms 236, and the equal and opposite forces exterted by springs 245 against the arm 242 extending downwardly from shaft 237. When the adjustable hand wheels 232 and 262 are manipulated to adjust the position of pulley 225 and the tension in spring 253, respectively, so that pointers 251 and 263 register with the centers of dials 252 and 26 4, respectively, the tension control mechanism is set for balancing the web tensions before and after perforating unit 24. However, when either of the hand wheels 232 or 262 is manipulated from the position corresponding to the balanced setting, the equilibrium of the forces acting on arms 235 and 236 and links 239, considered as a unit, is upset and such unit is displaced a small angular extent about shafts 237 and 238 to assume a new equilibrium position which corresponds to a tension differential which is maintained between the web sections before and after perforating unit 24.

When hand wheels 232 and 262 are set so as to obtain an equilibrium of forces with balanced web tensions before and after perforating unit 24, the described tension control mechanism will operate to maintain the desired balanced tension condition. Thus, if an abnormal reduction or slackening in web tension develops after perforating unit 24, that is, to the right of unit 24, as viewed in FIG. 1, the resulting inequality in the tensions before and after perforating unit 24 will cause arms 235 and 236 to pivot clockwise about the axes of shafts 237 and 238 so as to tend to equalize the web tensions before and after the perforating unit. Such pivoting of arms 235 and 236 connected by links 239 causes corresponding turning of shaft 237 which results in proportional upward movement of take-up pulley 241, thereby decreasing the tension in belt 216 and correspondingly increasing the contact radius of belt 216 with variable diameter pulley 217 and correspondingly decreasing the rotational speed of pulley 217 and shaft 218, and hence of cylinders 174 and 176 of perforating unit 24. This decrease in rotational speed of cylinders 174 and 176, and the resulting decrease in the speed of travel of web W through perforating unit 24 is proportional to the initially assumed abnormal reduction in web tension after the perforating unit and is suflicient to restore the tension after perforating unit 24 to its desired value, that is, to a value equal to the tension in the web in advance of perforating unit 24.

Similarly, if there is an abnormal reduction or slackening in the web tension in advance of perforating unit 24, the resulting inequality between the web tensions before and after perforating unit 24 causes arms 235 and 236 to pivot, as a unit, in the counterclockwise direction about shafts 237 and 238, respectively, so as to tend to balance the unequal web tensions, and such pivotal movement produces a proportional downward movement of take-up pulley 241. The downward movement of take-up pulley 241 increases the tension in V-belt 216 and proportionately decreases the contact radius of that belt with variable diameter pulley 217, whereby there is a proportional increase in the rotational speed of pulley 217 and shaft 218, and hence in the rotational speed of cylinders 174 and 176 of perforating unit 24. This increase in the t0- tational speed of cylinders 174 and 176 results in an increase in the speed of travel of web W through perforating unit 24 which is proportional to the initially assumed abnormal decrease in web tension between perforating units 23 and 24 and is sufficient to restore the web tension to its desired value.

In view of the previously described balancing of forces which act on the unit consisting of arms 235 and 236 and links 239 in the equilibrium position of that unit, it will be apparent that the adjustment of hand wheel 232 in the direction for causing downward movement of pulley 225, and hence an increase in the initial tension in V-belt 216 would cause a corresponding increase in the force acting upwardly on take-up pulley 241, and which tends to pivot arms 235 and 236 in the clockwise direction, as viewed in FIG. 1, but this tendency can be overcome by manipulating hand wheel 262 so as to cause a corresponding increase in the tension in spring 253 which tends to pivot arms 235 and 236 in the counterclockwise direction. Since the increase in tension in V-belt 216 reduces the radius of contact of that belt with variable diameter pulley 217, and thereby increases the rotational speed of cylinders 174 and 176 of perforating unit 24, with a corresponding increase in the Web tension between units 23 and 24, the increase effected in the tension of spring 253 would establish an equilibrium position for the arms 235 and 236 at which the tension in web W after perforating unit 24 is equal to the increased value of Web tension in advance of the perforating unit. Thus, even when it is desired to maintain equal web tensions before and after perforating unit 24, hand wheels 232 and 262 can be manipulated to either increase or decrease the equal web tensions which are to be maintained.

Further, when the position of pulley 225 or the tension in spring 253 is altered so as to cause a shifting of the equilibrium position of arms 235 and 236 in the direction causing downward displacement of take-up pulley 241, the corresponding increase in the tension of belt 216 causes reduction in the radius of contact of that belt with variable diameter pulley 217 and thereby proportionally increases the rotational speed of cylinders 174 and 176 of perforating unit 24, so as to increase the web tension before the perforating unit and decrease the web tension after the perforating unit, and to subsequently maintain this differential in the web tensions. Similarly, if the tension in spring 253 is reduced below the setting for the balanced web tension condition, arms 235 and 236 move to a new equilibrium position and, during such movement, take-up pulley 241 is moved upwardly to decrease the tension in V-belt 216 and thereby increase the radius of contact of such belt with variable diameter pulley 217 causing a corresponding decrease in the rotational speed of cylinders 174 and 176 of perforating unit 24. Such decrease in the rotational speed of cylinders 174 and 176 tends to increase the tension in the web after perforating unit 24 with respect to the tension in the web in front of the perforating unit, and the differential in the web tensions thus created is subsequently maintained.

From the above detailed description of an illustrative embodiment of the invention, it will be apparent that a rotary perforating device has been provided that can be easily maintained, and that is effective to maintain accurate longitudinal and transverse registration of perforations formed in the web with respect to preprinted patterns on the web, while accurately establishing and maintaining desired tension conditions in the web, even during high speed operation.

It is to be understood that the transverse perforating unit 23 and the longitudinal perforating unit 24 are adapted to be used individually when it is required to perforate the Web W only along transversely extending rows or along longitudinally extending rows, respectively. Further, although the perforating units 23 and 24 of the illustrated embodiment cooperate to form rectangular patterns of holes in the Web, as is apparent in FIG. 7, rotary perforating devices embodying the invention may be designed to form differently shaped and dimensioned patterns of holes or perforations in the Web.

Although an illustrative embodiment of the invention has been described in detail herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to that precise embodiment, and that various changes and modifications may be effected therein Without departing from the scope or spirit of the invention, except as defined in the appended claim.

What is claimed is:

A rotary perforating device for forming holes in a printed web having repetitive printed patterns thereon and transverse and longitudinal register marks in predetermined positional relationship to the printed patterns; said device comprising a set of rotated male and female die cylinders having perforating pins and die holes, respectively, cooperating to form perforations in the printed web as the latter passes between said rotated cylinders; a longitudinal register control mechanism including a roller contacting the printed web before said cylinders and being movable to advance and retard the web with respect to said cylinders, and motor means operative to effect the web advancing and retarding movements of said roller; a transverse register control mechanism including roller means contacting the printed web before said cylinders and being movable axially and in a tilting sense to transversely displace the Web with respect to said cylinders, and motor means operative to effect the movements of said roller means for transversely displacing the web; first photoelectric web scanning means actuated by the longitudinal register marks of the Web to emit register signals representing the longitudinal position of the web as a function of time; selector switch means driven in synchronism with said cylinders and emitting uniformly intermittent signals representing the rotational positions of said cylinders as a function of time and which occur simultaneously with said register signals upon correct longitudinal registration of the printed patterns of the web with respect to the perforations formed in the web by said cylinders; control means operating said motor means of the longitudinal register control mechanism in response to any deviation between the occurrence of said register signals and the corresponding signals from said selector switch means to move said roller in the direction for restoring said correct longitudinal registration; second photoelectric web scanning means actuated by the transverse register mark of the web to emit a signal having an amplitude corresponding to the transverse position of the web relative to said cylinders; and control means operating said motor means of the transverse register control mechanism in response to the deviation of the amplitude of the signal from said second web scanning means from a predetermined value corresponding to correct transverse registration of said printed pattern with respect to said perforations, thereby to restore said correct transverse registration.

References Cited by the Examiner UNITED STATES PATENTS 1,822,902 9/1931 Osborne 22621 2,266,759 12/1941 Huck 83367 X 2,716,026 8/1955 Axworthy 226-21 2,994,783 8/1961 Looschen 83-367 X 3,025,740 3/1962 Sorkin 83-365 X ANDREW R. JUHASZ, Primary Examiner. 

